Crimping method and apparatus



Oct. 2, 1962 J. A. WISE 3,056,445

CRIMPING METHOD AND APPARATUS Filed 001;. 11, 1957 4 Sheets-Sheet 1 INVENTOR.

Joseph H. \rfise BY M Wr W94 Oct. 2, 1962 J. A. WISE CRIMPING METHOD AND APPARATUS Filed Oct. ll, 1957 4 Sheets-Sheet INVENTOR.

Oct. 2, 1962 J. A. WISE 3,056,445

CRIMPING METHOD AND APPARATUS Filed Oct. 11, 1957 4 Sheets-Sheet s J 1 u \9 a a I o In, z- V 3 v O; Q Q

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CRIMPING METHOD AND APPARATUS Filed Oct. 11, 1957 4 Sheets-Sheet 4 I H! mu "m" .AHHIHA .ni Him. .m

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atent 3,856,445 Patented Oct. 2, 1962 Flee 3,656,445 CRIMPING METHOD AND APPARATUS Joseph A. Wise, Camp Hill, Pa., assignor to AMP Incorporated, Harrisburg, Pa. Filed Oct. 11, 1957, Ser. No. 689,658 4 Claims. (Cl. 153-1) This invention relates to methods and machines for crimping ferrules and particularly to the crimping of terminals and connectors onto Wires.

Electrical connectors or terminals of the type which are adapted to be crimped onto wires are frequently produced in strip form in which each connector or terminal is connected to the next adjacent terminal so that they can be applied by means of an automatic or semiautomatic crimping machine which detaches the end one of the terminals from the strip and crimps it onto a wire. The present invention relates to methods and machines for crimping such terminals onto conductors and presents improvements which relate particularly to the feeding of the terminals to the crimping zone and to the severing of the end terminals from the strip. In the description which follows, the invention is disclosed with reference to the crimping of simple U-shaped terminals which are adapted to join two or more wires together, or toform a terminal on the end of a single wire, however, the invention is not limited to only this type of terminal but is applicable generally to automatic or semiautomatic crimping methods and machines and to a wide variety of terminal types.

In the accompanying drawing:

FIGURE 1 is a perspective view of a crimping machine in accordance with the invention;

FIGURES 2 and 3 are fragmentary views, with some parts broken away and others omitted in the interest of clarity, looking from the rear of the machine as viewed in FIGURE 1 and showing the ram and its actuating mechanism in different positions during the crimping cycle;

FIGURE 4 is a fragmentary top plan View showing the terminal strip feeding mechanism and the crimping dies in accordance with the invention;

FIGURE 5 is a view taken along the line VV of FIGURE 4;

FIGURE 6 is an exploded view showing a. pair of guide plates for the terminal strip which forms part of the invention;

FIGURE 7 is a frontal view of the feeding mechanism as shown in FIGURE 4;

FIGURES 8, 9, and are fragmentary views illustrating the action of the crimping dies during a crimping cycle in accordance with the invention; and

FIGURES l1 and 12 are fragmentary views showing the crimping die set and its associated supporting structure in the open and the closed position.

One preferred embodiment of the invention comprises a crimping press which, as disclosed, is horizontally disposed and is contained within a housing or frame 2 having a removable cover plate 4 and an arm or extension 6 which is recessed as at 8 for the accommodation of the crimping die set. As shown in FIGURE 4, the ram 12 is contained between the side of housing 2 and a bearing or guide 10 which may be integral with housing 2. Ram 12 is pivoted at its end to a link 14, as shown in FIGURES 2 and 3, and this link in turn is pivotly connected at 16 to a bell crank 18. The bell crank is pivoted intermediate its ends at 24} to a mounting plate 21 which is adjustably anchored as indicated at 22 to the housing 2. It is preferable to provide adjustability for pivot point 20 as disclosed in order to permit variation of the travel of the ram 12 for terminals of different sizes.

Bell crank 18 is also pivoted at 24 to the end of a piston rod 26 of a double acting piston-cylinder 28 having fluid inlets 30 at each end. The piston cylinder is pivotally anchored at 32 to the housing of the press in order to permit such limited movement of the cylinder as is necessary when the location of pivot point 28 is changed by adjustment of the adjusting means 22. It will be apparent from what has been said that upon actuation of piston cylinder 28, ram 12 is driven rightwardly as viewed in FIGURE 2 and link 14 is straightened and aligned with the ram while bell crank 18 is pivoted about pivot point 20.

An anvil 36 is secured to the end of ram 12 by means of fasteners 34 (FIGURE 11) for reciprocable movement towards and away from a fixed die block 60. Terminals in strip form are fed transversely across the face of this anvil as shown best in FIGURES 8-10, so that the anvil will sever the leading terminal from the strip and transport it towards the fixed crimping die. The side of this anvil which faces the strip of fed terminals is cut away near its end as indicated at 35 to define a shoulder 37 and on the very end of the anvil an additional shoulder 39 is formed. These shoulders sever connecting slugs which remain when the end of the terminals is removed as explained in detail below.

As best shown in FIGURES 1, 4 and 11 a terminal carrier 38 is slidably mounted on anvil 36 and provides a slot 40, which receives the anvil, having an enlarged mouth 42. The terminal carrier is engaged by the end of a rod 44, the opposite end of which is received within a recess in ram 12 as indicated at 46, a compression spring 50 being provided at the bottom of the recess to permit the carrier to be moved relatively towards the ram against the compression of this spring which otherwise normally maintains the carrier in the position of FIGURE 11. Carrier 38 is also slidably carried, by means of a dove tail or similar connection, by a support block 52 which is adjustably secured by means of screws 55 to a bracket 48 which in turn is fastened onto the end of ram 12. It is desirable to permit adjustment of support block 52 as shown in the drawing for the purpose of adapting the machines to terminals of different sizes which might entail varying amplitudes of travel of the terminal carrier relative to the fixed anvil.

The fixed crimping die structure comprises a die block 60, FIGURE 4, having die surfaces 62'. thereon, which is secured to a die block carrier 66 by means for changing the position of this carrier since the crimping operation is usually a very precise one and demands exact positioning of the die relative to the reciprocable anvil. In the disclosed embodiment, the die block carrier 66 is secured by means of fasteners 70 to an adjustable bearing block 68 and is laterally movable relative to the bearing block by virtue of an adjusting screw 72. This screw is received within a boss 74 extending from bearing block 68 and enters a threaded opening in die block carrier 66. The adjustable bearing block 68 abuts a pair of wedges 76 which provide arms having threaded openings for reception of an adjusting screw 78 having reduced diameter portions 82 and 84 which are received within slots in the arm extension 6 of the machine frame. A thumb piece 86 is provided on the end of this adjusting screw and the threads of the screw extend in opposite directions so that upon turning of this adjusting screw in one direction wedges 76 are moved relatively towards each other thereby to move bearing block 68 and carrier block 66 towards the ram as viewed in FIGURE 4 while rotation of this adjusting screw in the opposite direction moves these wedges away from each other and permits the bearing block to be moved away from the ram as viewed in thi figure. Set screws 88 extend through a cover plate 89 and through oversized slots in the bearing block so that it can be locked in any desired position relative to the ram. Advantageously, bearing block 68 is spring biased towards the wedges so that any slack in the anchoring of the block is taken up. This spring biasing of block 68 is accomplished by means of a screw 87 which extends through an opening in extension 6 and is threadedly received by block 68. A spring 86 is interposed between the head of screw 87 and the base of a counter bore of the opening through which the screw extends.

The terminal feed mechanism is mounted on the machine housing or frame by means of a support 96 which is secured to the frame of the press by means of fasteners 98 and this support in turn adjustably mounts a bracket 100 by means of set screws 102 which extend through slots 103. Bracket 100* is integral with a plate 106, which extends in a vertical plane in the disclosed embodiment and upon which are mounted the various components of the terminal feeding assembly. Plate 106 is provided with a central groove 108 along which the terminals are fed as indicated at 110 from a suitable substantially endless source as described below. Intermittent feeding of the terminals is accomplished by means of a finger 112 pivotally mounted between a pair of ears 114 on a pin 116. It is desirable to provide spring means for maintaining the feed finger in contact with the strip of terminals and this may be accomplished by the use of a bifurcated end portion on the finger, which is received between the ears, and a spring 120 which normally urges the finger against the strip of terminals as shown in FIG- URE 7 but which permits the finger to move relatively away from the strip.

Ears 114 project from a reciprocable slide 122 mounted between rails 124 on the face of plate 106. An extension 126 projects from one face of thi reciprocable slide through an oversize slot 128 in plate 106 and has secured to its end by means of a fastener 130 a connecting rod 132 which is coupled as at 134 by means of a threaded coupling to a piston rod 136 of a piston-cylinder 138. This piston-cylinder may be mounted on the face of plate 106 as shown in FIGURE 4 and advantageously can have secured thereto a guide rod 140 which extends through an opening in a stop 142. It will be understood that the travel of the piston rod and therefore, the travel of feed finger 112 can be adjusted by movement of stop 142 along piston rod 136. Piston-cylinder 138 may be of the simple single acting type having a compression spring around the piston rod within the cylinder to return the piston and the piston rod to the normal position. When this piston is actuated, piston rod 136 and connecting rod 132 move rightwardly as viewed in FIGURE 4 to cause plate 122 to move rightwardly as viewed in FIGURE 7. This plate of course carries the feed finger towards the crimping die set and feeds a single terminal into the crimping zone of the apparatus.

The present invention contemplates that the strip will undergo two feeding steps during each feeding cycle, a first feeding step for feeding a terminal between the die an anvil and a second feeding step to advance the strip a short distance in order to position the slug which connect the successive terminals in the path of the reciprocating anvil 36. This secondary or supplementary feeding of the strip 110 is accomplished by means of a projection 144 on slide 122 which presents a bearing surface 145 in alignment with a piston rod 146 of a piston cylinder 148. This piston cylinder is secured to plate 106 by means of a housing 150 and is supplied with compressed fluid from a line 152. It will be apparent from FIGURE 4 that the end of piston rod 146 contacts bearing surface 145 only when feed finger 112 and the piston rod 136 are in the retracted position (these parts being shown in the forward position after the completion of a terminal feed stroke in FIGURE 4).

It will be noted from FIGURE 4 that plate 106 does not extend up to the crimping die and anvil and that separate adapters are provided to guide the strip of terminals into the actual crimping zone. In the disclosed embodiment and for the simple U-shaped terminals shown, the adapters comprise a pair of interfitting plates 164, 166 which when together define an extension of terminal feed track 108. Plate 164 is provided near the end of the feed track with a rib or projection 168 which supports the U-shaped terminals as shown best in FIGURE 5 adjacent the plane of severance. These plates are removably secured to plate 106 by means of fasteners 170.

It is desirable to provide means to frictionally hold the strip of terminals within their feed track 108 and to anchor them against longitudinal movement other than the feeding movement. Such means is provided in the instant embodiment in the form of a plate 154 secured on the end of a bolt 156 which extends through mounting plate 106 and which provides an enlarged head 158. A helical spring 160 is interposed between head 158 of the bolt and the surface of plate 106 so that plate 154 is resiliently drawn against plate 106 and thereby tends to anchor the strip of terminals against accidental longitudinal movement. Advantageously adjusting screws 162 are provided in plate 154 to permit this device to be adjusted for terminals of varying heights. The strip of terminals may be supplied to the machine in any convenient manner. In the disclosed embodiment, the terminals are unwound from a reel 180 which is mounted on a spindle 182.

Microswitches 172, 174, FIGURE 2, are mounted in the housing in positions such that their closing is controlled by a contacting device 170 which is carried by ram 12. Switch 172 is located such that it is maintained in the closed position by contacting device 170 when the ram is in its top dead center position While switch 174 is momentarily closed when the ram reaches its bottom dead center position. An additional microswitch 176 is located adjacent connecting rod 132 and is adapted to be closed by this rod when it is in its rightward position as viewed in FIGURE 4. A main actuating switch (not specifically shown) is also provided which, when closed, initiates the crimping cycle.

Microswitch 172 is normally closed but is held open as shown in FIGURE 2 when the ram is in the top dead center position. When the main actuating switch is closed, air is supplied to the right hand side of cylinder 28 (as viewed in FIGURE 2) and the ram begins its travel toward the crimping die. Switch 172 is then opened as the contacting device moves rightwardly and activates 'a solenoid valve (not shown) which exhausts the air from terminal feed cylinder 128. The spring within cylinder 138 causes the piston therein to move leftwardly as viewed in FIGURE 4 thus retracting feed finger 112 and positioning bearing surface adjacent the end of piston rod 146. When the ram reaches its bottom dead center position, switch 174 (which is normally closed) is opened by contacting device (FIGURE 3) to cause the admission of air to the left hand side of cylinder 28 and at the same time supply air to cylinder 148 as viewed in FIGURE 2 thus causing return of the ram to its top dead center position. Simultaneously, as cylinder 148 is actuated, piston rod 146 moves rightwardly to feed the strip of terminals a short distance which is appropriately equal to the length of the tab or slug 178 which connects successive terminals 176 in the strip. Upon return of the ram to the top dead center position the slug is then sheared as shown in FIGURES 9 and 10 and the leading edge of the next adjacent terminal is deburred. It is intended that the term deburred should imply-that irregularities on the leading edge of the next adjacent terminal are removed and this edge is dressed or faced. When the ram returns to top dead center position, switch 172 is again opened to actuate a solenoid and admit air to feed cylinder 28. The next adjacent terminal is then positioned between the die and anvil and switch 176 is closed.

Switch 176 is closed when the next adjacent terminal is fed. This switch is connected in series with the main operating switch and thereby prevents initiation of a crimping cycle unless a terminal has been properly fed. In other words, if a terminal has not been fed, switch 176 will remain open and the cycle can not be initiated.

Changes in construction will occur to those skilled in the art and various apparently different modifications and embodiments may be made without departing from the scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective against the prior art.

I claim:

1. The method of forming crimped connections com prising the steps of, intermittently feeding a strip of connectors toward a crimping zone to position the end one of said connectors between a die set comprising one fixed die and one movable die having reentrant portions on its side, actuating said movable die to detach said end connector from said strip and crimp said connector onto a Wire, and feeding said strip a short distance to position edge portions of the next adjacent one of said connectors within said reentrant portions of said movable die Whereby, upon further travel of said die, said edge portions of said connector are deburred and surface irregularities thereon are removed.

2. Connector crimping apparatus comprising a fixed die and a movable die, means for feeding a succession of terminals in strip form while said dies are apart to position the leading terminal of said strip between said dies whereby, upon movement of said movable die towards said fixed die, said leading terminal is removed from said strip and crimped onto a Wire, said movable die having a recess therein, secondary feeding means for feeding said strip a short distance which is substantially less than the length of the terminals of said strip, and means for actuating said secondary feeding means during the interval when said dies are together whereby the next adjacent terminal of said strip is fed a short distance to position its leading end within said recess so that upon return movement of said movable die, said leading end is deburred and smoothed.

3. In a connector crimping apparatus of the type comprising, a fixed crimping die, a movable crimping die, means for feeding a strip of terminals along a feed path to position the leading terminal of said strip between said dies, and means operable upon movement of said movable crimping die for detaching said leading terminal from said strip and holding said leading terminal until said movable crimping die arrives at said fixed crimping die, the improvement comprising, a recess in said movable crimping die, said recess facing said feed path, means for feeding said strip a short distance substantially less than the pitch of said strip into said recess, and means for actuating said feeding means when said dies are together whereby, on the return stroke of said movable die, said recess deburrs the edge of the next adjacent terminal of said strip and removes irregularities on the edge of said next adjacent terminal.

4. Connector crimping apparatus comprising a fixed die, a movable die, a first feeding means for feeding a strip of terminals in end-to-end relationship along a path terminating at a location between said dies, said first feeding means having a stroke which is substantially the same as the length of said terminals, means for actuating said first feeding means when said terminals are apart whereby, the leading terminal of said strip is fed to a position between said dies, and upon movement of said movable die said leading terminal is detached from said strip and carried to said fixed die for attachment to a conductor, a recess in said movable die, a second feeding means for said strip, said second feeding means having a relatively short stroke which is substantially less than the length of the terminals of said strip, and means for actuating said second feeding means while said dies are together whereby the leading end of the next adjacent terminal of said strip is fed into said recess and upon return movement of said movable die, said leading end is deburred and smoothed.

References Cited in the file of this patent UNITED STATES PATENTS 1,599,356 Auspitzer Sept. 7, 1926 1,975,414 Wade Oct. 2, 1934 2,169,802 Keller Aug. 15, 1939 2,254,117 Keller Aug. 26, 1941 2,375,741 Dibner May 8, 1945 2,631,213 Martines Mar. 10, 1953 2,681,447 Davis June 22, 1954 2,690,562 Cootes Oct. 5, 1954 2,839,824 Berg June 24, 1958 2,915,755 Kincaid Dec. 8, 1959 

